Free floating sub-floor thermoplastic tile

ABSTRACT

A sub-floor tile is provided for use in a modular sub-floor tile system. The sub-floor tile has an upper surface and a lower surface made from one prefabricated, durable, water resistant, mould and mildew growth resistant thermoplastic elastomer with acoustic deadening properties. The lower surface has a series of projections extending away from the sub-floor tile and located adjacent to an underlying surface, such as concrete, when the sub-floor tile is in use. The projections create a space between the sub-floor tile and underlying surface creating a moisture barrier and increased air flow that also permits moisture drainage. This also permits a thermal break between the underlying surface and the overlying flooring surface, such as carpet, laminate, or vinyl.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims the benefit of U.S. Provisional Application No. 61/664,938, filed Jun. 27, 2012, the entire contents of which is hereby incorporated by reference herein.

BACKGROUND OF THE INVENTION

b 1. Field of the Invention

The present invention relates to sub-floor tiles and more particularly, to free floating sub-floor tiles for use in a modular sub-floor tile system capable of supporting a floor, such as carpet, laminate or vinyl, and having a water resistant, mold and mildew growth resistant, acoustic deadening lower surface that permits moisture drainage, air flow and prevents vapour condensation.

2. Description of Related Art

A finished floor typically consists of a sub-floor and a flooring surface such as carpet, laminate, or vinyl, which is supported by the sub-floor. The nature of a sub-floor will vary depending on the flooring surface it needs to support and the environment in which it must function. Existing sub-floors present several challenges, one of which is the possibility of moisture being present and another which is to insulate the floor from what could be a very cold underlying surface of poured concrete. Additionally, many sub-floors are labour intensive to install and rely on secure and frequent fastening to prevent movement between adjacent flooring sheets. Lastly, many sub-floors are made from materials, such as wood, that would damage in the event of a water leak or flood. Lastly, many sub-floors are made from a variety of material components that are held together with adhesives of some form, which diminish the sub-floors strength and durability.

SUMMARY OF THE INVENTION

Accordingly, it is an object of the present invention to provide an easy to install thermoplastic elastomer sub-floor tile all made from one material, capable of supporting any overlying flooring surface, providing acoustic deadening properties and further creating a moisture barrier allowing air circulation and preventing vapour condensation between the tiles and the underlying surface, permitting moisture drainage, and which is resilient to water leaks, floods, mold, mildew and chemical deterioration. Additionally, the present invention creates a thermal break between the underlying surface and overlying flooring surface, adding warmth and comfort.

With respect to the above, a sub-floor tile is provided for use in a modular sub-floor tile system. The sub-floor tile has an upper surface and a lower surface made from one prefabricated, durable, water resistant, mould and mildew growth resistant thermoplastic elastomer with acoustic deadening properties. The lower surface has a series of projections extending away from the sub-floor tile and located adjacent to an underlying surface, such as concrete, when the sub-floor tile is in use. The projections create a space between the sub-floor tile and underlying surface creating a moisture barrier and increased air flow that also permits moisture drainage. This also permits a thermal break between the underlying surface and the overlying flooring surface, such as carpet, laminate, or vinyl.

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments of the invention are described below with reference to the accompanying drawings, in which:

FIG. 1 is a perspective schematic view of the sub-floor tiles of the invention;

FIG. 2 is an underside view of a sub-floor tile showing the lower surface with a series of projections, 8 tongues projecting out from two of the sub-floor tiles edges, and 8 grooves recessed into two of the sub-floor tile edges;

FIG. 3 is a top view of a sub-floor tile showing the upper surface with 8 tongues projecting out from two of the sub-floor edges;

FIG. 4 is an underside perspective view of a sub-floor tile showing the lower surface with a series of projections, 8 tongues projecting out from two of the sub-floor tile edges, and 8 grooves recessed into two of the sub-floor tile edges; and

FIG. 5 is an enlarged elevation view of the sub-floor tile of FIG. 2 indicated in the circle 4, with one of the projections shown in sectional view.

DETAILED DESCRIPTION OF THE INVENTION

Reference is made to FIGS. 1, 2 and 4 to describe a preferred embodiment of the sub-floor tile, designated generally by the numeral 10. The sub-floor tile 10 includes an upper surface 12 with recessed pockets and a lower surface 14. The lower surface 14 is attached to the upper surface 12. The lower surface 14 may be formed of a resistant a thermoplastic elastomer or other suitable waterproof material and includes a plurality of projections 16 which rest on an underlying surface 11 to support the sub-floor tile 10 on the underlying surface 11 and allow moisture to drain between them and to permit air circulation between the sub-floor tile 10 and the underlying surface 11 when the sub-floor tile 10 is installed. FIG. 1 illustrates a series of sub-floor tiles 10 adjacent and interlocking with one another in a running bond pattern layout. In a preferred embodiment, the sub-floor tile 10 is attached to the adjacent sub-floor tile 10 using a tongue 18 and a groove 20 snap and lock arrangement, which will be described later.

The sub-floor tile 10 will now be described in more detail. As seen in FIG. 2, the sub-floor tile 10 is square, and is preferably manufactured as a 23.25″ by 23.25″ tile, although other sizes may also be manufactured.

In a preferred embodiment, the upper surface 12 and the lower surface 14 is a single unit made from a thermoplastic elastomer.

Turning now to FIG. 5, the projections 16 extend away from the lower surface 14 in the opposite direction to the upper surface 12. The projections 16 are frustoconical shaped with a bottom surface 24 and a cavity 26 extending from the bottom surface 24 towards the upper surface 12. Preferably the projections 16 are aligned in rows and columns. When the sub-floor tile 10 is installed, the bottom surface 24 of the projections 16 is located adjacent the underlying surface 11.

In order to connect adjacent sub-floor tiles, the sub-floor tile sides may be configured in a tongue and groove snap and lock arrangement. The edge of the upper surface 12 of each sub-floor tile 10 has eight tongues 18 protruding from two adjacent sides (four each side) and the edge of the upper surface 12 of each sub-floor tile 10 also has 8 grooves 20 recessed into each of the remaining sides with elongated wall spacers (four for each side). Each groove 20 is sized and operable to receive the tongue 18 to interconnect by snapping and locking adjacent sub-floor tiles and allow for space between the sub-floor tile 10 and perimeter walls during installation. The tongue 18 and groove 20 is formed during manufacturing of the sub-floor tile 10 by shaping the upper surface 12.

In use, a series of sub-floor tiles are interlocked and located on an underlying surface 11, shown in FIG. 1, and abutting walls 15. In the preferred embodiment, adjacent sub-floor tiles are interconnected using a tongue and groove snap and lock arrangement, wherein a plurality of identical adjoining tongues and grooves are snapped together and positioned in either a running bond pattern layout or in a stack bond pattern layout.

Although not illustrated, it will be appreciated that when the sub-floor tiles 10 have been installed over the underlying surface 11, an overlying flooring surface can be laid on top of the sub-floor tiles 10 and can be adapted to accept fasteners on the recessed pockets on the upper surface 12 during installation. Excess moisture can flow between the projections 16 and air can circulate between the sub-floor tiles 10 and the underlying surface 11.

It is to be appreciated that numerous modifications and variations may be made to the above-described invention(s) without departing from the scope of the invention(s) as defined in the appended claims. 

1. A sub-floor tile which permits moisture drainage, air flow and prevents vapour condensation, the sub-floor tile comprising: an upper surface; a lower surface, the upper and lower surface comprising a prefabricated, durable, water resistant, mould and mildew growth resistant, acoustic deadening material having a plurality of frustoconical projections extending away from the upper surface to support the upper surface above an underlying surface, to protect the upper surface from water, to permit free drainage of water about the projections and between the sub-floor tile and the underlying surface, to permit a thermal break between the underlying surface and the overlying flooring surface, and to create a moisture barrier and increased air flow between the underlying surface and the overlying flooring surface; and said upper surface having tongues located on two adjacent edges and grooves located on two adjacent edges for connecting the sub-floor tile to an adjacent sub-floor tile comprising corresponding tongues and corresponding grooves to prevent movement therebetween.
 2. The sub-floor tile according to claim 1, wherein the sub-floor tile is made from a thermoplastic elastomer.
 3. The sub-floor tile according to claim 1, wherein the sub-floor tile has a square shape.
 4. The sub-floor tile according to claim 4, wherein a size of the sub-floor tile is 23.25 inches by 23.25 inches.
 5. A plurality of sub-floor tiles, comprising: a first sub-floor tile and a second sub-floor tile, wherein each of the first and second sub-floor tiles is a sub-floor tile according to claim 1, and wherein an edge of the first sub-floor tile and an edge of the second sub-floor tile are configured to be connected together so as to prevent movement therebetween.
 6. A method of installing sub-floor tiles, comprising: positioning an entire first sub-floor tile and an entire second sub-floor tile onto an underlying surface, wherein each of the first and second sub-floor tiles is a sub-floor tile according to claim 1; and connecting the first and second sub-floor tiles together.
 7. The method according to claim 6, wherein the positioning comprises moving the entire first sub-floor tile with respect to the entire second sub-floor tile in a running bond pattern layout.
 8. The method according to claim 6, wherein the positioning comprises moving the entire first sub-floor tile with respect to the entire second sub-floor tile in a stack bond pattern layout. 